XPR 300 Pilot Arc Timeout

[JakeGG]

Having an issue where the table stops cutting on the second part of a job and gives a pilot arc timeout error message (error 521).

The program is setup to cut many parts, piercing for each one. It will cut the first part fine then when it comes down to pierce the second part there is a quick flash of blue light and it doesn’t cut. You can close the error message and start cutting again and it will do the same thing cutting one part then stopping.

Changing the consumables ‘fixes’ the problem, but the consumables we take out don’t look that worn (see attached pic). Causing us to go through a lot of consumables. Is there something else that may be causing the error?

[adbuch]

Where did you purchase the consumables?
David

[JakeGG]

Where did you purchase the consumables?
David

Lampton Welding Supply. They supposedly ship em straight from Hypertherm.

[AlphaTekErik]

Verify you are using the correct pierce height. if this is correct then you need to perform a torch lead test. page 313 of your XPR Manual

[weldguy]

Definitely physically check the pierce height with feeler gauges on the initial and second cut that doesn't work, shouldn't be a difference between the two but I would certainly check it. When the torch lifts up to the pierce height just pause the machine and measure. Get back with your results

[HypHyDef]

Hi JakeGG,
I forwarded your post to our technical support team here at Hypertherm and they wanted me to relay this message.

"I would have him call in to Tech Service or email us for more support, but sounds like it could be an issue with his Ohmic IHS. He is likely resorting to using stall force on his initial heigh sense and is getting some plate deflection and then the torch is not in the correct position to transfer to the plate. And If it is not that then could possibly be an issue with his gas flows.

Either way if he gives us a call or shoots us an email we can help resolve the issue".

Technical service
(800) 643-9878

[adbuch]

Hi JakeGG,
I forwarded your post to our technical support team here at Hypertherm and they wanted me to relay this message.

"I would have him call in to Tech Service or email us for more support, but sounds like it could be an issue with his Ohmic IHS. He is likely resorting to using stall force on his initial heigh sense and is getting some plate deflection and then the torch is not in the correct position to transfer to the plate. And If it is not that then could possibly be an issue with his gas flows.

Either way if he gives us a call or shoots us an email we can help resolve the issue".

Technical service
(800) 643-9878

[adbuch]

Very much agreed! Piercing too low can reek havoc on electrodes. There is a good reason why the pierce height is generally at least twice the cut height. And cutting too low will be just as bad. I think it was already mentioned, but you might want to pause your machine while cutting and physically measure your actual cut height.
David

[JakeGG]

Solved. For now. Hypertherm Informed me that the 'pilot arc timeout' error 521 means that an arc was formed but the current is not sufficient to cut. Can be caused by the pierce height being too high or the plate not being sufficiently grounded. Hypertherm guy told me to connect jumper cables from the plate to the ground at the back of the machine. I did this and the error went away.

[adbuch]

Solved. For now. Hypertherm Informed me that the 'pilot arc timeout' error 521 means that an arc was formed but the current is not sufficient to cut. Can be caused by the pierce height being too high or the plate not being sufficiently grounded. Hypertherm guy told me to connect jumper cables from the plate to the ground at the back of the machine. I did this and the error went away.

[JakeGG]

Well.. the problem is back. Still have the jumper cables attached. Even switched out the consumables to new and problem still there.

In regards to physically measuring the pierce height - when you pause the job on an xpr 300 the torch will raise up. Perhaps I could flip the lever on the electrical box during a pierce but I'm concerned there may be some electrical damage to the machine if I try this.

[weldguy]

Well.. the problem is back. Still have the jumper cables attached. Even switched out the consumables to new and problem still there.

In regards to physically measuring the pierce height - when you pause the job on an xpr 300 the torch will raise up. Perhaps I could flip the lever on the electrical box during a pierce but I'm concerned there may be some electrical damage to the machine if I try this.

Bummer...

Does your screen have a DRO showing the Z position during the pierce? If so write this down and then you can just jog the Z back down to that value and do an actual physical measurement with feeler gauges.

[JakeGG]

Updating after a year. We run the machine and get the pilot arc timeout error daily. Operator is required to stand at the machine and press "ok" to close the pop up and then start the cut again. Hypertherm had a handful of things to try to fix the machine like checking circuit boards and machine grounding but the cost to get the hypertherm tech out here was high (150/hr travel pay and 200/hr while working) and the boss decided its not worth the money... instead make the operator stand at the machine and restart the cut each time the error pops up.

[ColoradoJJones]

Updating after a year. We run the machine and get the pilot arc timeout error daily. Operator is required to stand at the machine and press "ok" to close the pop up and then start the cut again. Hypertherm had a handful of things to try to fix the machine like checking circuit boards and machine grounding but the cost to get the hypertherm tech out here was high (150/hr travel pay and 200/hr while working) and the boss decided its not worth the money... instead make the operator stand at the machine and restart the cut each time the error pops up.

Talk about stepping over a dollar to pick up a nickel.

What about support from the table manufacturer? what table, controller, and software are you running? Edge and ProNest?

[weldguy]

That's a bummer. Oh well, sometimes when you live with the issue you end up figuring it out over time. Thanks for posting back.

[JakeGG]

Finally resolved. It was the contacts located inside of the power supply that had turned black and after cleaning them it solved the problem. We were forced to finally tear apart the power supply when the error came up more and more frequently until we couldn't cut at all.

[weldguy]

Fantastic that you posted back with your solution. Thanks. Pretty surprised and disappointed Hypertherm tech couldn't figure that out. Like I said in my earlier post "Oh well, sometimes when you live with the issue you end up figuring it out over time."